Choose your solution. Blow Molding

Transcription

1 Choose your solution Blow Molding

2 PET blow molding: 30 years of experience From an ambitious challenge started in the early 1980 s to the high technology of the SBO Universal2, Sidel has explored all the paths of innovation in order to meet market requirements for blow molder reliability and productivity as well as for package quality Sidel takes up the PET challenge The first SBO is sold in Great Britain for carbonated beverages The world s fastest machine (SBO 40) 36,000 bottles per hour: that s the new record for the SBO 40 which crosses the Atlantic to run in a U.S. customer s plant Development of the Preferential Heating process This process enables optimum material distribution for complex shapes and flat bottles First dual-cavity SBO for small containers The first SBO 48/38 blows 50,000 small bottles per hour, or 14 bottles per second: a world record Invention of the Heat Resistance (HR) technology Sidel invents a solution for hot-fillable and pasteurizable packages First PET jars The first SBO 16 WM (Wide Mouth) packages parmesan cheese in the U.S. at a speed of 13,000 jars per hour Creation of the «Quick-Change» system Bottle format changeovers are now ultra-quick Integrated blowingfilling-capping: The Sidel Combi revolution Conveyor-less, more compact, cleaner and more economical: the Combi is a new alternative for complete lines. 2 _ Blowing solutions

3 1999 Actis barrier technology This plasma process increases the shelf life of carbonated and oxygen-sensitive beverages bottled in PET SBO Compact: The first linear blow molder The SBO Compact range produces bottles up to 10 liters in size and runs at a maximum speed of 6,400 bottles per hour Equinox: The first self-regulation system for blow molding Integrated into the blow molder, the Equinox system ensures the production of PET bottles with optimal, consistent quality SBO Universal: The third generation of blow molders Higher speed, improved performance and better ergonomics: nearly 800 machines have been sold since this range was released on the market SBO Highspeed: High speeds for small formats The SBO 34 Highspeed runs at a speed of 61,200 bottles per hour. Predis dry decontamination of preforms An innovative dry decontamination system for preforms, using hydrogen peroxide (H 2 O 2 ) vapor, for the bottling of sensitive products After the launch of the SBO Universal2 at 2000 bottles per mold in 2009, the SBO Universal2 Eco saves up to 45% on power consumption. 3

4 Blowing solutions adapted to your product Resistant and transparent, PET offers alternatives for bottle shapes and formats as well as unprecedented lightweighting possibilities. These are qualities that have already conquered the water, CSD, juice and tea markets, and which are proving increasingly attractive for the dairy and household product markets. Regardless of what product you are packaging, Sidel s blow molder range provides you with solutions for all formats, output rates and processes. Still water & sparkling water Bottle capacity Min./max. output rates in bottles per hour Blow molder range Up to 0.75 liter 48,000-64,600 SBO Highspeed Up to 2.25 liters 12,000-54,000 SBO Universal2 Up to 3.0 liters 6,400-36,000 SBO Compact / SBO Universal Up to 6.0 liters Up to 4,050 SBO Compact XL Up to 10 liters Up to 2,400 SBO Compact XXL Csd & beer Bottle capacity Min./max. output rates in bottles per hour Blow molder range Up to 0.75 liter 48,000-64,600 SBO Highspeed Up to 2.25 liters 12,000-54,000 SBO Universal2 Up to 3.0 liters 6,400-36,000 SBO Compact / SBO Universal Up to 6.0 liters Up to 4,050 SBO Compact XL Up to 10 liters Up to 2,400 SBO Compact XXL Milk and dairy products Bottle capacity Min./max. output rates in bottles per hour Blow molder range Up to 0.75 liter 48,000-64,600 SBO Highspeed Up to 2.25 liters 12,000-54,000 SBO Universal2 Up to 3.0 liters 6,400-36,000 SBO Compact / SBO Universal 4 _ Blowing solutions

5 Juices, teas and isotonic drinks Package type Standard Heat resistant (for hot fill or pasteurization) Bottle capacity Min./max. output rates in bottles per hour Blow molder range Up to 0.75 liter 48,000-64,600 SBO Highspeed Up to 2.25 liters 12,000-54,000 SBO Universal2 Up to 3.0 liters 6,400-36,000 SBO Compact / SBO Universal Up to 6.0 liters Up to 4,050 SBO Compact XL Up to 10 liters Up to 2,400 SBO Compact XXL Up to 2 liters 10,800-51,000 SBO Universal HR Wines and spirits Package type Complex and asymmetrical Standard Bottle capacity Min./max. output rates in bottles per hour Blow molder range Up to 3.0 liters Up to 5,600 SBO Compact PH 8,400-28,000 SBO Universal PH Up to 0.75 liter 48,000-64,600 SBO Highspeed Up to 2.25 liters 12,000-54,000 SBO Universal2 Up to 3.0 liters 6,400-36,000 SBO Compact / SBO Universal Up to 6.0 liters Up to 4,050 SBO Compact XL Up to 10 liters Up to 2,400 SBO Compact XXL Oils, sauces and condiments Package type Complex and asymmetrical Standard Bottle capacity Min./max. output rates in bottles per hour Blow molder range Up to 3.0 liters Up to 5,600 SBO Compact PH 8,400-28,000 SBO Universal PH Up to 0.75 liter 48,000-64,600 SBO Highspeed Up to 2.25 liters 12,000-54,000 SBO Universal2 Up to 3.0 liters 6,400-36,000 SBO Compact / SBO Universal Up to 6.0 liters Up to 4,050 SBO Compact XL Up to 10 liters Up to 2,400 SBO Compact XXL Household products, cosmetics and pharmaceuticals Package type Complex and asymmetrical Standard Bottle capacity Min./max. output rates in bottles per hour Blow molder range Up to 3.0 liters Up to 5,600 SBO Compact PH 8,400-28,000 SBO Universal PH Up to 0.75 liter 48,000-64,600 SBO Highspeed Up to 2.25 liters 12,000-54,000 SBO Universal 2 Up to 3.0 liters 6,400-36,000 SBO Compact / SBO Universal Up to 6.0 liters Up to 4,050 SBO Compact XL Up to 10 liters Up to 2,400 SBO Compact XXL 5

6 SBO Universal Blow Molder Range For high line efficiency Sidel s rotary blow molders satisfy performance requirements and signal Sidel s commitment to bottle quality, while also optimizing operating costs. With SBO Universal and the latest SBO Universal2 blow molders, output rates are high, and production reliability is ensured. The SBO Universal machine ranges are backed by Sidel s 30 years of blow molding expertise and by its continuous improvement programs. This leads to more productive and more robust machines that help lower production costs. SBO Universal2: 10% increase in output rate Robustness and reliability: for guaranteed outputs Very fast machines: output rates up to 2,000 bottles per hour per mold, guaranteed 97% efficiency. Optimized productivity and production costs: continuous improvement program. Robust kinematics specially adapted to an output rate of 2,000 bottles per hour per mold: resized transmission and braking, great stability of movements. Limited mechanical risks: reinforced spindle chain and transfer arms, more powerful engine. Wide process window: an oven with 40 and 50 mm pitch guaranteeing a large heating reserve and sufficient heating times for high output. New automation architecture: new electrical rotary union to improve data flow rates, centralized PLC boards in the electrical cabinet to obtain shorter solenoid valve response times. Optimized electricity consumption: reflectors are close to the preforms in the oven, new generation of lamps that consume 10% less power. Preform feeder reliability: speed regulation loop from the elevating column to the orienting rollers, unjamming of nested preforms, regulation of preform levels. Preforms move through the safe, high-yield oven: reinforced spindle chain. Stability and precision of preform and bottle transfers: robust arms reinforced with two springs, articulated grips on an individual rotating axis. Transfer safety: no interference between the transfer arms and the nozzle actuator thanks to a nozzle safety up-cam. Fewer maintenance operations: robust components limit the risk of breakage. More robust blow molders move into higher gear The SBO Universal2 range has higher output rates: up to 2,000 bottles per hour per mold 2 - The reinforced spindle chain ensures safe passage of the preforms through the oven at high speeds. 3 - Arms are reinforced with two springs to guarantee stable, precise transfer of preforms and bottles. 6 _ Blowing solutions

7 SBO Universal and SBO Universal2: Speeds up to 54,000 bph SBO 6 SBO 8 SBO 10 SBO 14 SBO 16 SBO 20 SBO 24 SBO 26 SBO 30 Output rates 12,000 16,000 20,000 28,000 32,000 40,000 45,600 49,400 54,000 (up to, in bph)* *bottles per hour - Maximum mechanical output rate 7

8 8 _ Blowing solutions

9 SBO Universal and SBO Universal2 Optimized bottle cost Sidel s SBO Universal range reduces energy consumption and maintenance costs, in order to optimize bottle production costs. This range continues to evolve with the new oven Ecoven, which reduces power consumption by more than 40%. Energy consumption under control New oven Ecoven: Reduced Power Consumption Integrating the cylinder, solenoid and flow limiter significantly reduces dead space in the air circuits and cuts down on blowing air consumption. Additional savings of 15% on air consumption: optional exhaust air recovery system. The compressor can be downsized thanks to the drop in air consumption. Process adjustments in real time: instantaneous report on blow molder electricity consumption is available in the central control station. The latest addition to the SBO Universal 2 range, now equipped with the new Ecoven, decreases oven power consumption by more than 40%. Changes in the oven configuration help lower installed power up to 43% and heating time by up to 15%: Fewer oven modules Fewer lamps per module (8 instead of 9) Smaller oven footprint. The greater precision of preform heat treatment ensures that the bottles will have technical characteristics and quality identical to the performance levels offered by the SBO Universal range of blow molders. Proposed on all models of the SBO Universal range, this new system can also be adapted to existing machines and to Combi units. Combi Universal: An alternative to traditional lines SBO Universal available in Combi configuration, an integrated blowing-filling-capping solution, Higher yields than with a traditional line: no intermediate equipment, Combi configurations for all products, including for sensitive products with Combi Predis. In the Combi version, SBO Universal machines offer higher yields than with a traditional line The new mold base concept (in the up position) reduces format changeover times. 2 - With less dead space at the blowing station, low air consumption costs are guaranteed. 3 - A new brushed aluminum housing makes maintenance of the blowing machine s exterior a breeze. 9

10 Ergonomic Blow Molders Simplified maintenance operations Ease of intervention for format changeover: quick change system and mold base in the up position. Less greasing: maintenance-free components (synthetic rollers, etc.) and centralized lubrication of the blowing wheel. Parts changed less frequently: parts are more robust, with optimized service life. Simplified exterior maintenance: brushed aluminum housing. Bottle Switch: Less Than a Minute to Change a Mold The new, Sidel-patented quick format changeover system improves machine flexibility by reducing the mold changeover time in order to adapt to faster product changeover times on the filler. This means that intermediate storage silo or palletizing solutions are no longer of use. The principle involves a simple, semi-automatic solution: This results in improved productivity: A 50% drop in machine downtime and therefore greater availability. This new system is available in Options & Upgrades for all of the most recent generations of SBO Universal blow molders, for all SBO Series 2 and Combi machines. The required blowing station is positioned in front of the operator with automatic opening of the mold-support units by simplified unlocking for implementation safety. Mold changeover by insertion / removal in / from the mold-support units with no tools needed and a simple system of use for perfect ergonomics. Production restart is configured from the PCC The required blowing station is positioned in front of the operator with automatic opening of the mold-support units. 2/3 - Mold changeover by insertion/removal in/from the mold-support units with no tools. 10 _ Blowing solutions

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12 SBO Universal and SBO Universal2 Bottle quality commitment To meet the diverse needs of the bottling market and satisfy lightweighting requirements, SBO Universal blow molders offer customized blow molding processes as a function of bottle weight, contents and shape complexity. A wide processability window Large heating reserve available with the oven. Regulation of the distribution and penetration ovens. Heating profile controlled from the control panel. Optimized material distribution and lightweighting possibilities: adjustment of individual lamp parameters, and independent management of electrical cabinets in the oven. No heating-related neck deformation: neck-down heating technology. Blow molding station: Where the bottle takes shape No neck deformation: Sidel-patented bell nozzle to keep the neck under isobaric conditions (no mechanical stress is exerted on the neck). Optimal molding: quick blowing response time. Bottle base quality: cooling circuit in the mold base. Packages under control to ensure quality and lightweighting, for significant savings on PET: Pressco vision system to control weight in each zone for preforms and bottles. Hygiene under control Hygiene in the blow molder enclosure: casing with no soundproofing foam, grease-free components. Food safety in the blow molder: SBO designed in accordance with the HACCP method (HA = Hazard Analysis + CCP = Critical Control Point). Various hygiene options are available: hopper cover, UV rail for preform treatment, preform dedusting, Predis dry decontamination of preforms, and oven air filtration. 12 _ Blowing solutions

13 Technical data SBO Universal and SBO Universal 2 Applications Bottle capacity Multi-products 0.25 l - 3 l Output rates (bottles per hour) 10,800-54,000 Range SBO 6 to SBO 30 Oven pitch Maximum neck diameter Maximum neck height Maximum preform height under neck Maximum bottle diameter Maximum bottle height under neck Maximum base height 40 mm et 50 mm 48.5 mm 35 mm 145 mm 130 mm 340 mm 51 mm The SBO Universal blow molder range covers many applications, shapes and sizes. 2 - Pressco control systems guarantee bottle quality. 3 - The oven s large heating reserve and full control of blow molding parameters ensure a wide process window for these machines. 13

14 SBO Highspeed For the on-to-go market 64,600 bottles per hour: that s the highest speed for the SBO Highspeed blow molder range. The equipment meets a dual objective: to offer very high output rates for the single-serve PET bottle market, and to reduce operating costs by improving productivity. Sidel s goal is clear: anticipate and adapt to changes on the liquid product market. The SBO Highspeed blow molder range was born to respond to increasing on-the-go consumption and to meet the need for the very high-speed production of single-serve bottles ranging from 0.2 to 0.75 liters. These blow molders are based on the proven principles of the SBO Universal range, with which they share a large number of components for greater standardization of parts. Operating costs cut Inspired by the SBO Universal range Reduced operating costs: optimized spare parts costs and energy efficiency. Less air consumption, due to a 40 mm cylinder and an optional exhaust air recycling system. Very fast production changeover times: it takes two operators 60 minutes on an SBO 34 XS Highspeed and less than 45 minutes on an SBO 24 XS Highspeed to perform a changeover. Reduced maintenance times: to help limit machine shutdowns and boost line productivity. Compact design of the SBO Highspeed range: based on the frame of an SBO 20 Universal blow molder, to reduce the cost of logistics, installation and start of production. Optimized bottle shapes: lighter bottles, more complex shapes, and molds designed for very high speeds. The oven is particularly well-suited to small containers: spindle chain with 40 mm pitch, and a heating module with six lamps (lower installed capacity). A wide process window: radiation oven, and all oven lamps are controlled from the control panel. User-friendly interface: special adaptations for high output rates offer unmatched user-friendliness. Customized preform feeder to match machine speed. It uses a large-capacity hopper for longer operation without replenishment (40 minutes on average, depending on preform type). Mechanics designed for high speeds: specific kinematics to ensure precise transfers at high outputs, deployed in a compact system with specific accommodations for small mold support units. Innovative mold support unit: compact for packages with maximum diameters of 75 mm, unique opening/closing mechanisms to limit operational gaps and deformations that naturally occur at higher speeds. The patented SBO Universal mold base system, which is usually up, has been revamped. High-speed production for small bottles The blow molding station, equipped with a 40 mm cylinder, cuts air consumption. 2 - The SBO Highspeed features a 40 mm pitch spindle chain and radiation oven for heating precision and process flexibility. 3 - The mold support unit is very compact. The unique mold opening/closing mechanisms limit operational gaps and deformations that naturally occur at higher speeds. 4 - An extremely user-friendly operator interface is designed especially for high outputs. 14 _ Blowing solutions

15 Technical data SBO 24 XS SBO 34 XS Applications Small, multi-product containers Small, multi-product containers Bottle capacity 0.2 l l 0.2 l l Maximum output rate (bottles per hour) 48,000 64,600 Number of molds Oven pitch 40 mm 40 mm Number of oven modules Number of lamps per oven module 6 6 Maximum neck diameter 38.5 mm 38.5 mm Maximum neck height 25 mm 25 mm Maximum preform height under neck 90 mm 90 mm Maximum bottle diameter 75 mm 75 mm Bottle height under neck 254 mm 254 mm 15

16 SBO Compact SBO standards for linear machines The SBO Compact is the entry-level range of SBO blow molders for outputs between 2,400 and 6,400 bottles per hour and sizes from 0.25 L to 10 L. They are based on Sidel s good design practices and include innovative concepts. SBO Compact machines combine linear architecture with the standards that have made SBO blow molders famous: heating modules, blow molding station, customized parts and genuine Sidel molds. A simple concept A compact machine Interchangeable customized parts Linear architecture in modules: integrated preform feeder, linear oven, transfer table, blow molding station. Linear transfer: two sets of grips, one for oven / mold preform transfer and the other for bottle transfer between the molds and the bottle outfeed. Blow molding station: two to four molds in line. Small footprint: easy layout (5,1 m x 2 m x 3,5 m). Plug and blow concept: subassemblies are mounted on the same frame, pre-set and pre-wired at the factory. Easy handling and shipment in a 20-foot container (or 40 foot with preform feeder). Quick installation in just one day, and technical acceptance in five days. Universal Quick Change shell molds can be used with a special spacer and a Shellbridge for small formats. Customized parts are identical to those for the SBO Universal range: transfer grips and spindle noses. Linear blow molders for speeds up to 6,400 bph 16 _ Blowing solutions

17 Unmatched productivity The SBO Compact range uses the latest technological advances to ensure high yields and simplified machine operation. Reliable and robust Ergonomic and flexible 100% positive transfer by the neck: already proven at high output with the SBO Universal range. The cam-controlled movements are perfectly synchronized and repetitive. Reliable transfers: pitch changes for the preform transfer grips are controlled by cam (patented process). Possible optimization of heating and blowing times depending on the package, without interfering with transfer time: constant mechanical cycle thanks to independent motor drive for oven/blow molder transfer (Simotion). 100% mechanical drive concept: the blow molding station is controlled by a patented cam system mounted on a single shaft for mold opening / closing, mold locking / unlocking and mold base up / down movements. No early wear on molds: pneumatic compensation. User-friendly operator station: touch screen integrated into the frame, supervision of blow molder controls and settings. Quick format changeover: no adjustments during individual replacement of each shell mold and mold base support. For example, an operator can change formats in 10 to 15 minutes (same neck). Fewer customized parts: neck transfer between the preform feeder rail and the blow molding station, bell-shaped nozzle available for a large range of bottles. Perfect accessibility, and simplified maintenance and settings: eight doors positioned around the circumference of the blow molder, distinct modules for each function. Options available to optimize flexibility, hygiene and production costs A small footprint makes layout easier. 2 - All cams driving the blow molding stations are mounted on a single shaft % mechanical control of the blow molding station. 4 - Individual electrical cabinets to control heating modules are offset. 5/6 - Format changeover takes barely 15 minutes. 17

18 The SBO Compact 3XL and SBO Compact 2XXL blow respectively bottles up to 6 and 10 liters. 2 - Preforms go through four rotations in front of the heating modules equipped with 9 to 12 lamps. 3 - The cooling ramps keep the necks at low temperature. 4 - The linear transfer of preforms ensures precise, repetitive movements. 5 - SBO Universal-type blow molding blocks improve response times and molding. 18 _ Blowing solutions

19 SBO Compact Flawless bottle quality Just like SBO Universal, the SBO Compact range offers the best possible process conditions in order to satisfy all bottle design specifications, while also offering lightweighting possibilities. Fully controlled heating process Wide heating range: five modules, identical to those for SBO, for the most demanding processes, without compromising on output rate. Precise management of heating zones: individual control of lamps from the control station, customized number of heating zones, progressive pitch lamp rack. Controlled heating profile for optimum material distribution: four full rotations of the preforms in front of each heating module. Lightweighting possibilities: homogenous material distribution, process expertise. Bottle quality up to any test Proven blow molding circuit, identical to that used with SBO Universal. Quick response times for the blow molder solenoid valves: preform takes cavity shape quickly, and optimized maintenance time during blow molding. Almost invisible parting line for impeccable bottle appearance: mechanical locking of the mold and pneumatic compensation of blowing pressure. Bottle quality: neck transfer minimizes scratching on the preform body. Guaranteed bottle neck integrity No neck deformation: water cooling in the ramps on both the reflector and lamp sides, and patented isobaric bell-shaped blowing nozzles. Neck ventilation at 100% power, independent of the regulated ventilation of the preform body. Protection of mechanical parts on the spindle: water cooling in the ramps. DeepGrip: Innovative blown handle for large-format packages For the consumer: Ease of handling. For the manufacturer: No add-on handle (deep blown grip). Technology : Punching-conforming Target markets: Edible oil, water, household goods and cosmetics. Technical data SBO 4 Compact SBO Compact 3XL SBO Compact 2XXL Applications Multi-products Multi-products Multi-products Bottle capacity L (specific applications: 3 L) L L Maximum output rate (bottles per hour) 6,400 4,050 2,400 Number of molds Oven pitch 60 mm 76 mm 120 mm Number of heating modules Number of lamps per heating module Maximum neck diameter 38.5 mm (specific applications: 48.5 mm) 55 mm 55 mm Maximum neck height 25 mm (specific applications: 35 mm) 35 mm 35 mm Maximum preform height under neck 145 mm 205 mm 205 mm Maximum bottle diameter 115 mm (specific for steel molds 117 mm) 180 mm 212 mm Maximum bottle height under neck 348 mm 420 mm 420 mm 19

20 SBO Universal HR Performance for optimum production Sidel s proven technology and expertise are unmatched in the field of heat-resistant package production: its SBO Universal HR blow molder range enables the production of heat-set PET bottles. HR-specific configuration Energy consumption under control Optimized maintenance costs Special HR kinematics to manufacture 1,800 bottles per hour per mold: quick mold opening /closing, and reinforced transfer arms for greater stability. Aluminum HR molds: these lighter molds ensure high speeds and prevent mechanical wear of the machine for greater productivity. Less air consumption: the built-in nozzle actuator, solenoid valve and flow limiter assembly considerably reduces dead space in the air circuits. Additional savings of 15% on air consumption: optional exhaust air recovery system. The compressor can be downsized thanks to the drop in air consumption. Less electricity use for the oven: individual lamp regulation from the central control station, new generation of more economical lamps. Process adjustments in real time: instantaneous report on blow molder electricity consumption is available in the central control station. Ease of intervention for format changeover: quick change system and mold base in the up position. Parts changed less frequently: parts are more robust, with optimized service life. The HR process The HR (heat resistant) process makes packages that can withstand either hot filling or pasteurization. It uses a process known as heat setting, which combines higher preform heating temperatures with a longer contact time between the bottle and hot mold. This combination guarantees: The rearrangement of molecular chains at low stress levels, which limits the effects of any subsequent uncontrolled shrinkage, An average increase in the degree of crystallinity of 32% (reducing the heat-sensitive amorphous phase), which improves heat resistance. For hot-fillable or pasteurizable PET bottles 20 _ Blowing solutions

21 HR kinematics quick mold opening/closing and more stable transfer arms guarantee higher output rates. 2 - The built-in nozzle actuator, solenoid valve and flow limiter assembly considerably reduces blow molding air consumption. 3 - Lightweight F300 aluminum makes faster production rates and format changeover times possible. 4 - For each bottle capacity, Sidel offers specific HR mold formats like Jumbo molds for large containers. 21

22 SBO Universal HR Bottle quality assurance Optimal process conditions Regular bottle profile Specific HR package design Wide processability window: large heating reserve available with the oven. Modular heating: regulation of the distribution and penetration ovens. No heating-related neck deformation: neck-down heating technology and independent mechanical adjustment of the cooling ramps in the oven, bell nozzle for neck protection during the blow molding phase. Lightweighting possibilities thanks to adjustment of individual lamp parameters, independent management of the oven s electrical cabinets and an optimized blow molding process. Fully controlled material distribution and bottle quality appearance: preblow air pressures are independently parameterized from the central control station, repetitive process. Lower volume variation: individual adjustment of cooling time (40 bar air injection to cool the internal wall of the bottle). Bottle shape maintenance: PET s memory effect decreases on contact with the hot mold. Wide selection of HR bottle shapes: expertise in the specific design of preforms and bottles. Improved preform neck resistance: crystallized or extra-thick neck. Design of packages with specific performance levels in terms of shape, weight and filling tolerance. Overstroke base: Just one bottle for hot fill or aseptic The overstroke base is an elegant alternative to the traditional solution of flexible panels designed on the bottle body to absorb volume variations. It opens up new shape possibilities that until now could not be used on this type of bottle, while also ensuring better visual impact on consumers. A single bottle shape can be used regardless of the bottling technology in use: Hot fill or aseptic. Sidel s unique solution is based on the management of process sequencing, thanks to very precise automation control of Sidel blow molders: The bottle is pre-blown before the base has entered the mold. The mold base then rises higher than the level of a traditional mold base, lifting the material between the body wall and the mold base to create a small circular lip that significantly stiffens the diameter of the bottle support. The patented bottle base profile acts like a membrane or piston. 22 _ Blowing solutions

23 Innovative packages for hot filling of sensitive products FreeShape The first PET bottle that can be used for the packaging of sensitive beverages aseptically or by hot fill with a single shape and panel free, thanks to the overstroke base technology. - Capacity: 0.5 L - Weight: 28 g - Speed: Up to 1,500 b/h/m Online filling at 85 C Curvy Lightweight bottle with an innovative shape. - Capacity: 0.5 L - Weight: 28 g - Speed: Up to 1,800 b/h/m Online filling at 85 C Skyward Lightweight bottle with an innovative shape. - Capacity: 0.5 L - Weight: 19.9 g - Speed: Up to 1,800 b/h/m Online filling at 90 C Output rates up to 51,000 bottles per hour SBO 6/8HR SBO 8/10HR SBO 10/14HR SBO 14/20HR SBO 16/20HR SBO 20/24HR SBO 24/24HR SB0 26/30HR SBO 30/36HR Output rates* (up to, in bph) 10,800 14,400 18,000 25,200 28,800 36,000 43,200 44,200 51,000 *bottles per hour Maximum mechanical output rate with F300 aluminum or steel molds with weight limits. Preform and bottle specifications Applications Bottle capacity Maximum neck diameter Maximum neck height Maximum preform height under neck Maximum bottle diameter Maximum bottle height under neck SBO Universal HR Juices, teas, coffee and isotonic drinks Up to 2 liters 48.5 mm 35 mm 145 mm Up to 130 mm 340 mm 23

24 SBO Universal PH and SBO Compact PH Preferential Heating: the process The Preferential Heating process is ideal for producing plastic packaging such as flat bottles or asymmetrical containers. The SBO Universal PH and SBO Compact PH blow molder ranges use Sidel s in-depth knowledge of complex packaging design. The limits of the standard process Preferential Heating: Unfailing quality Uniform heating process to blow a complex container: uniform distribution of material in all directions during bi-orientation, which is unsuitable for complex or asymmetrical shapes. Unsatisfactory bottle appearance for complex shapes: areas of overthickness appear on the longer sides of the container. Compensate for process limits with an optimized preform: a smaller diameter and greater thickness improve stretching of the material in the narrower sections of the mold. However, this can create undulations on the panels in the finished package (panel-in effect) and therefore less possibility for lightweighting. Customized heating profile: the reflectors positioned opposite the infrared lamps of the distribution oven have a series of reflecting and non-reflecting zones. This selective heating ensures that the preform expands to take the specific shape of the cavity. Repeatability of the differentiated heating profile: constant rotation of the preforms is guaranteed (movement past the non-reflecting zones, at lower temperature, and the heating zones via direct and reflected light). Package quality: the angular position of the preform is controlled throughout transfer, with mechanical orientation in the oven and perfect preform positioning in the mold (pivoting transfer arms with controlled grips and a four-stroke bell nozzle). Optimum material distribution: no areas of over-thickness, easier labeling, optimized bottle weights and a wide choice of preforms. Why choose Preferential Heating? The Preferential Heating process is ideal where the ratio between the large and small sides of a container is greater than 2. Length (L) / Width (W) L W 2 = Preferential Heating Preferential Heating for flat or asymmetric containers L W Sauces or condiments. 2 - Detergents and household products. 3 - Alcoholic beverages. 4 - Cosmetics and personal care. 24 _ Blowing solutions

25 3 distribution oven penetration oven 1 The preforms rotate continuously as they pass between the infrared lamps and the reflectors. 2 In the penetration oven, the light beams are both direct and reflected. 3 In the distribution oven, the reflected light is eliminated on certain sections of the preform which generates alternating hot and cold zones on the preform. 4 Pivoting arms fitted with controlled grips position the preform at the right place in the cavity. 25

26 A team dedicated to packaging development will assist you in creating innovative, tailor-made solutions which meet all the requirements of the product. 2 - The series of light-reflected and dark zones ensure good material distribution. 3 - Returning to standard production is possible with a simple reconfiguration of the machine. 4 - The SBO Compact PH linear transfer arms are fitted with controlled opening / closing grips to maintain the angular position of the preforms inside the mold. 5 - The Universal Shell mold guarantees cavity quality for complex packaging profiles. 26 _ Blowing solutions

27 SBO Universal PH and SBO Compact PH Guarantee of reliability and performance Patented since 1994, Sidel s exclusive Preferential Heating technology is used on the latest generations of Sidel blow molders. Proven technology Optimal productivity Wide range of applications: highadded-value, technically complex packaging for use with household products, cosmetics and pharmaceuticals, sauces and condiments as well as some alcoholic beverages. Sidel s expertise in designing highly technical packages: the guarantee of perfect package / process compatibility. Nearly 100 Preferential Heating blow molders are in production around the world. Sidel s rotary and linear blow molders are reliable and robust. High efficiency: the pivoting transfer arms and the controlled grips guarantee reliable transfers. Reversible machine: interchangeability of the vented reflectors (preferential heating) with standard reflectors, replacement of the pivoting transfer arms with standard arms. Technical data Applications SBO Universal PH Household products, pharmaceuticals, cosmetics. Sauces or condiments SBO Compact PH Household products, pharmaceuticals, cosmetics. Sauces or condiments Bottle capacity L (3.3 L for specific applications) L (3 L for specific applications) Maximum output rate (bottles per hour) 8,400 28,000 5,600 Number of molds Number of heating modules Number of lamps per oven module 9 9 Oven pitch 50 mm 60 mm Maximum neck diameter 48.5 mm 48.5 mm Maximum neck height 35 mm 35 mm Maximum bottle diameter 117 mm (130 mm for specific applications) 115 mm (117 mm for specific applications) Maximum bottle height under neck 340 mm 340 mm Neck indexation option Available Under development Neck indexation Certain types of packaging require the necks to be indexed. Thanks to a pivoting neck, the cap is screwed to the end of the thread in a position which is predetermined with regard to the shape of the container. It s a simple way of orienting the filler heads, the pistol caps, to improve flow in the opposite direction from handling. The thread has a pin or a notch on the neck-ring to reference its orientation. A mechanical cam-based system indexes the spindles as they rotate. The position of the thread on the neck is taken into account by the mechanical set-up of the oven and the transfers, so that it coincides with the profile of the cavity. 27

28 Combi: A winning strategy for the entire line Sidel blow molders are available not only for standalone machines but also in Combi configuration: a combined blowing-filling-capping solution. A competitive alternative to traditional lines. A configuration adapted to your production goals Hygiene under control: Guaranteed food safety Lower bottle costs Diversity of applications, for all food and non-food liquids in PET packaging: still or sparkling water, CSD, juices, milk or other dairy products, sauces or detergents. Available for a wide range of output rates: from 10,000 to more than 60,000 bottles per hour. Optimized line layout: small footprint. A customized Combi for all products Controlled production environment: single Combi enclosure, no conveying, accumulation or intermediate storage. Cleaning and sanitation levels for the product circuits and machine surfaces are adapted to the product s requirements: CIP (Clean In Place), SIP (Sterilization In Place), COP (Cleaning Outside in Place), SOP (Sterilization Outside in Place). Protection of the external environment, which consists of the space between the filling/capping carousel and the walls of the chamber. Protection levels in the enclosure vary depending on the needs of the product being filled: closed chamber, isolator, aerolic protection (filtered air, sterile laminar air flow ISO 5 to 7). Various hygiene options: the preform hopper comes with a cover, preform feeder rail with UV, preform dedusting, dry decontamination of preforms with Predis or caps with Capdis, filtered air in the oven, etc. Efficiency is 2 to 4% higher than for standalone machines: no intermediate equipment between the blow molder and filler. Reliability: synchronization of blow molding and filling functions, positive neck transfer by wheels with the bottles continuously grasped under the neck between the various functions. Greater freedom of shapes and bottle lightweighting: positive transfer of bottles between blow molding and filling. Lower energy consumption (air, electricity, water). With lighter packaging, energy needs are lower for heat treatment of the preform, and the blow air pressure is lower as well. Improved machine availability: shorter format changeover times. 28 _ Blowing solutions

29 The Combi, a blow molding-filling-capping solution, offers a competitive alternative to traditional lines % positive transfer by wheels, with constant under-neck bottle support between the different functions, ensuring performance reliability. 3 - The Combi is especially well-suited to high-speed lines. 4 - The Combi concept is built on highly reliable rotary kinematics and perfectly synchronized blow molding and filling. 29

30 Dry Decontamination of Preforms Predis: Simply Aseptic Predis is a dry decontamination technology for preforms developed on the Sidel Combi. This process ensures high quality for sensitive products, whether distributed at room temperature or in the cold chain: UHT milk, ESL dairy products, fruit juices, preservative-free CSD, teas and water. It is also used to maintain or even extend the life of these products. A unique concept A simple concept Sidel put to work its expertise in preform decontamination in order to develop a groundbreaking technology. Predis, a method of dry decontamination for preforms, uses hydrogen peroxide vapor. It was developed on the Sidel Combi, an integrated blowing, filling, capping machine: Under a constantly controlled atmosphere, the system ensures the reduction of microorganisms between the preform and the filled and then capped bottle. Unlike bottle decontamination, this concept is simple, economical and environmentally friendly. The system employs H 2 O 2 as a sterilizing agent because it is relatively simple to use. Preforms are transferred by the neck on a wheel from the preform infeed to the oven entrance where Predis is located. First, the hydrogen peroxide (H 2 O 2 ) is vaporized. Next, calibrated nozzles deposit the H 2 O 2 as condensation onto the internal walls of the preform. Steam flow parameters are defined in a recipe and regulated by high-performance mass flow meters to ensure complete process stability. The preforms are then heated in the oven to a temperature of 100 C, which ensures H 2 O 2 activation. UV-C lamps in the oven ensure decontamination of the outside walls of the preforms. Bottles are blown using 0.01 micron filtered air after which they are transferred by the neck in the Combi s controlled atmosphere. This guarantees that no recontamination occurs through the fillingcapping phase. 30 _ Blowing solutions

31 Predis: Simply Aseptic Neck decontamination by UV light during preform infeed Dedusting with filtered air inside the preforms Predis: H 2 O 2 vapors on the inside walls of the preform H 2 O 2 activated in the oven Decontamination of the outside wall of the preform using UV light H 2 O 2 activated in the oven Preform transfer under controlled air Bottle blown with sterile air Bottle transfer under controlled air 31

32 Decontaminate the preform rather than the bottle Easy-to-use system An economical solution It is easier to decontaminate a small container with a processing surface that is 6 to 12 times smaller than that of a bottle. Decontamination is more efficient on the smooth interior wall of a preform as opposed to a bottle shape customized by ribs, a waist or engraving that can make the even distribution of the sterilizing product difficult. Preform decontamination allows total freedom of bottle shapes because the empty bottle does not undergo any thermal stress and, consequently, experiences no deformation. Predis is extremely simple to use and reliable. It requires less equipment and less space than a solution with a rinser. Critical points are analyzed in an HACCP (Hazard Analysis Critical Control Point) program. They are continuously managed and monitored by a controller. User-friendly operation from a single operator station means that just one person is needed to supervise all of the production steps, from preform feeding to the filledcapped bottle. Preform decontamination parameters are included in the bottle format recipe, making format change-overs easier. The advantages of Predis, the Combi, and the pairing of these two contribute to substantial savings over traditional solutions on the market. Predis is a dry decontamination system that requires no water consumption and very little consumption of chemical products (from 5-15 mg per preform, which is 40 times less than a system using dry decontamination on a bottle). The Combi itself offers numerous benefits. With Sidel s Combi, no silo or air conveying is needed and its configuration is far simpler requiring up to 30 percent less space. Furthermore, the Combi is two to four percent more efficient than an in line concept. Combining the Combi and Predis offers great bottle lightweighting potential thanks to continuous by-the-neck transfers and the absence of any thermal stress on the empty bottles. Without a rinser, the process is far less complex; there are fewer mechanical parts; maintenance and labor costs are reduced. There is an overall five percent energy savings compared to an in line process. 32 _ Blowing solutions

33 A secure production Environmentally friendly Predis guarantees reliable decontamination. The even distribution of the sterilizing agent on the internal walls of the preform, flow and temperature control of the H 2 O 2 vapor (with extremely precise mass flow meters) and the flow control based on preform characteristics ensure perfect decontamination. The fact that preforms must pass through the oven for the bottle process guarantees activation of the H 2 O 2 in all preforms. The Combi equipped with Predis ensures a totally secure production process where all bottles are blown from decontaminated preforms. The absence of a rinser guarantees product safety because there is no water residue and very little sterilizing agent is used. In addition to consuming no water, Predis also consumes very little energy and generates no liquid effluents, which helps protect the environment. Because of the compact design of Predis, a Predis-equipped Combi system takes up no more space than a standard Combi. 33

34 Packaging & Tooling Center A single contact for all packaging solutions With 30 years of experience in package design and development, and more than 5,000 new shapes and 22,000 molds produced each year, Sidel confirms its position as the world s leading creator of PET packaging. A bottle that promotes brand image Sidel anticipates market needs and focuses on innovation by putting its expertise and creativity at the service of differentiating your package: Esthetic and innovative: Two designers and 16 drafters, 5,000 drawings and 300 bottle designs per year. Robust and easy to use: Industrially qualified packages (feasibility, laboratory tests). Economical: Optimized shapes, lightweighting, lower energy consumption. Environmental: Lightweighting, new materials, recyclability. Product integrity: Package/product compatibility studied by the Sensitive Products Center. FreeShape: A single package for brand image FreeShape is the first PET bottle that can be used to package sensitive beverages both aseptically and by hot fill, while retaining the same shape. It s a development that combines a deep knowledge of material characteristics and mastery of molding-blowing technologies. The result is a bottle with no panels and an extremely resistant base, obtained with the overstroke base technology. 34 _ Blowing solutions

35 Meeting consumers expectations Sidel creates innovative bottles in terms of design, performance and materials that meet consumer expectations: attractive, economical and recyclable packages. SmartWeight: A lightweight, highperformance package SafeSense: A package to preserve product integrity EcoLoop: An eco-friendly package DeepGrip: An ergonomic package SmartWeight is a lightweight bottle less than 10 g for still water that makes no compromise on quality. Its stiff base and its wider diameter ensure safe mechanical performance for bottlers and real comfort of use for consumers. SafeSense is the first PE bottle transformed by injection stretch blow molding. Its quality of appearance, its sealing ability and its mechanical performance are equivalent to PET. Making it an optimal solution for the recycling of opaque bottles. EcoLoop: A PET bottle containing a large fraction of recycled material for the bottling of sparkling water. Thanks to the SBO Universal 2 equiped with the EcoOven, this high-quality, eco-friendly package also has strong economic benefits. Produced at high speeds, it can reduce energy consumption by up to 40%. DeepGrip is a large-format PET bottle, for water and oil, integrating a deep handle for consumer comfort. Elegant, with a triangular shape, DeepGrip has a blown handle, with no need for an add-on handle, thanks to the patented punchingconforming technology. 35

36 Performance of a network The package is a veritable marketing issue, in which the blow mold is key. With Sidel s Packaging & Tooling Center (PTC), you can profit from the know-how and experience of the world leader in packaging and blow molding of plastic bottles. You will get innovative solutions, optimized costs and a short time to market for your packages. The know-how of a major group present all over the world with five Packaging & Tooling Center (PTC): France, USA, Brazil, Mexico and China. Dedicated teams: 270 experts and engineers who are close to customers. Local manufacture with world-class quality. Responsiveness: lead times as short as three weeks for a set of Universal standard molds. Quality commitment and compliance with technical specifications. A full range of molds and customized parts With its full range of molds and customized parts, Sidel relies on a unique concept: the Universal Shell mold. This mold adapts to all generations of Sidel blow molders as well as competitor machines. 22,000 molds produced each year. Versatility: all applications, bottles from 0.3 to 10 L in size. Flexibility: molds are compatible with blow molders from Sidel and other manufacturers. Modular molds (inserts, ) that are interchangeable between blow molders (Shellbridge, Multiblower, etc.). Adaptability: standard, HR, aseptic molds, etc. Robustness: the most resistant aluminum alloys (7022) are used. Manufacturer s quality warranty: 2,000 genuine customized part kits per year. Innovations: Kohlox (wear rings and studs made from self-lubricating composite material to reduce maintenance), equick Change (format changeover times reduced by 50%). equick Change: Format changeover times reduced by 50% Kohlox: Grease-free molds Modulomold inserts: A single mold, several bottle shapes Sidel s patented equick Change system is available as an option on all the latest generations of Sidel blow molders (SBO Universal, SBO Series 2 and SBO Series 2+). It allows ultrafast connection of the cooling circuit to the mold neck with just one click. All of the piping that feeds the neck circuits with water and the electrical cables for the temperature probes are connected and disconnected in less than five seconds. This leads to a 50% time savings with respect to the quick change version. Implementation is extremely simple: a single part to handle and just four operations to perform without any tools! The equick Change system is perfectly adapted to HR molds (Heat Resistance). Saving two minutes per mold on weekly maintenance: that is the goal of the new wear rings and the new studs made from Kohlox, a self-lubricating composite material. Launched by Sidel on the occasion of Drinktec 2009, these new grease-free parts mean that all greasing/degreasing steps can be eliminated, providing substantial savings of both time and money. This means cleaner molds, reduced mechanical wear on parts and a lighter mold base to adapt to new blow molder speeds of up to 2,000 bottles per hour per mold. Patented by Sidel, this technology can be adapted to existing molds. To respond to productivity needs as well as the customization of packages, the patented Modulomold technology of removable inserts can be used to produce several bottles of the same size in a single mold. The shoulder alone, the lower part of the mold body or both can be customized. The solution is characterized by a fixed labeling zone and the same mold base for all bottle shapes of the same size. Ultra-quick changeover, in 20 seconds for a set of inserts, can be done without tools. A mistake-proofing system reduces the risk of errors during mold installation. The complete solution includes a trolley that is specially adapted to insert changeover operations. 36 _ Blowing solutions